Project 7332: the 2012 Bay Area Maker Faire.Warhammer 40,000 Space Marine Build Part 2: the Ba.My Halo Spartan costumes weigh around 50 pounds, so building the Space Marine the same way would probably mean building a 200 pound costume. Laying up fiberglass or rotocasting resin pieces would amount to too much weight. Since the wearer will be walking on very high platform shoes and his maneuverability will already be restricted, it's a bad idea to make him heavy as well. The main challenge with a costume of this size is keeping the weight manageable. This way it can be appropriately intimidating: Instead, we decided to engineer the costume so that the finished character is the full height. Having looked at other fan-made Space Marine costumes, they all seem to fail in the scale department.
Still, after a bit of deliberation, Matt and I figured it'd be best not to scale down any of the parts at all. According to the WH40K mythology, Space Marines are supposed to be over seven feet tall in bare feet. The first order of business was to determine how much we should scale down the parts in order to make them wearable.
